Method and apparatus for the creation of a tool

ABSTRACT

An apparatus  10  and a method  50  for the creation of a tool  40 . The apparatus  10  and the method  50  allow for dynamic measurement of the tool  40  as it is being created and further allows for the use of positive feedback to increase the likelihood that the produced tool will be structurally similar to a certain model. The apparatus  10  and method  50  further allow sections of varying thicknesses to be used and provide a technique to create surfaces which further increase the likelihood that the produced tool will be structurally equivalent to a desired and modeled tool.

This application is a continuation of application(s) nonprovisionalapplication No. 09/741,928 filed on Dec. 20, 2000, now U.S. Pat. No.6,587,742.

FIELD OF THE INVENTION

The present invention generally relates to a method and an apparatus forthe creation of a tool and more particularly, to a method and anapparatus for selectively and efficiently creating a tool by the use ofa mathematical and/or computer generated model of the tool and thecreation of sections which are later operatively bound, therebyco-operatively forming the tool.

BACKGROUND OF THE INVENTION

A tool, such as a mold, die, or other multi-dimensional object, iscommonly used to selectively produce relatively large amounts ofsubstantially identical objects. The tool may also be formed intoseveral portions or parts which cooperatively produce these objects.

Traditionally, such a tool is produced by the use of a substantiallysolid block of material which is “shaped” (e.g., by cutting and/orgrinding) into a desired form. Several blocks may be needed for certaintools having various parts or portions. This method, although capable ofproducing the desired tool, is relatively costly, is highly inefficient,and is not capable of rapidly producing a tool to meet the demands ofthe tooling industry.

In order to reduce the cost and expense associated with the productionof the tool in the previously delineated manner and in order to allow atool to be “rapidly” produced, a “laminar process” or method isalternatively employed. Such a laminar technique requires the initialcreation of a multi-dimensional mathematical or “computer based” toolmodel. The model is then partitioned in order to create various tool ormodel “partitions.” These intangible partitions are then used to formand are physically manifested within sections of material which are thensequentially stacked and bonded to cooperatively form a structure whichapproximates the structure of the desired tool. While this laminartechnique does reduce overall production costs and does allow a tool tobe rapidly produced, it does not reliably produce a structure which hasa form which is substantially similar to that of the desired tool.

That is, the laminar process fails to account for variances in thematerial used to form the sections, the spacing between sections causedby the bonding material, as well as various other variances. The laminarprocess also fails to determine, as the process proceeds, how well theincompletely or partially formed structure approximates the portion ofthe tool to which it corresponds and fails to allow for dynamicmodification of the process to correct and/or to operatively“counteract” irregularities and/or structural faults.

Hence, oftentimes a structure is produced which does not readilyapproximate the tool, thereby undesirably increasing the cost andexpense associated with the formation of the tool since the resultantstructure must either be discarded or “reworked”. Moreover, the laminarprocess also utilizes substantially identical partition and sectionalwidths which prevent the use of relatively wide sections to createportions of the tool having a substantially constant width, therebyreducing the number of needed and/or utilized sections and significantlyreducing overall production cost and expense. The laminar process alsodoes not account for height variances within a single tool partition,oftentimes eliminating important structural aspects of the tool from theproduced structure, and is not readily adapted for use in a completelyand/or substantially completely automated environment due to its failureto provide dynamic feedback signals representing the accuracy of theoverall tool building process.

There is therefore a need for a new and improved process for quickly andefficiently producing a tool and which overcomes some or all of thepreviously delineated drawbacks of prior tool producing methods andprocesses, and there is therefore a need for an apparatus to performthis new and improved process. Applicants' invention addresses theseneeds and represents such a new and improved tool forming process andapparatus.

SUMMARY OF THE INVENTION

It is a first non-limiting advantage of the present invention to providea method and apparatus for the creation of a tool which overcomes someor all of the previously delineated drawbacks of prior tool formingmethods and apparatuses.

It is a second non-limiting advantage of the present invention toprovide a method and an apparatus for the creation of a tool whichovercomes some or all of the previously delineated drawbacks of priortool forming methods and apparatuses and which dynamically andsubstantially ensures that the produced structure desirably approximatesthe corresponding structure of the tool by the use of positive feedbacksignals which are based on certain thickness measurements.

It is a third non-limiting advantage of the present invention to providea method and an apparatus for the creation of a tool which overcomessome or all of the previously delineated drawbacks of prior methods andapparatuses and which allows sections of varying widths to beselectively and dynamically created, thereby reducing the overall toolproduction cost and expense.

It is a fourth non-limiting advantage of the present invention toprovide a method and an apparatus for the creation of a tool whichovercomes some or all of the previously delineated drawbacks of priormethods and apparatuses and which utilizes the height of each end of apartition of the model to create a section which may be used to create arelatively cost effective tool structure which more closely approximatesthat partition then current techniques, thereby allowing a tool to beselectively, efficiently, and accurately produced.

According to a first aspect of the present invention, a method forcreating a tool is provided. The method includes the steps of creating amodel of the tool; creating a first partition of the model; creating afirst section from the first partition; measuring the section; using themeasurement to create a second partition of the model; creating a secondsection from the second partition; and attaching the second section tothe first section, thereby forming a tool.

According to a second aspect of the present invention, a method forcreating a tool is provided. The method includes the steps of creating amodel of the tool; creating a first partition of the model; creating afirst section having a first width by use of the first partition of themodel; creating a second partition of the model; creating a secondsection having a second width by use of the second partition of themodel; and attaching the second section to the first section, therebyforming the tool.

According to a third aspect of the present invention, a method forforming a tool is provided. The method includes the steps of creating amodel of the tool; creating a plurality of partitions from the model,each of the plurality of partitions having respective first and secondends of a certain respective height; and creating a section for each ofthe plurality of partitions, each section having first and second endsand each of the first and second ends having a substantially similar andrespective height which is equal to the height of the first end of thepartition to which that section pertains only when the height of thefirst end of the partition to which that section pertains is larger thanor equal to the height of the second end of the partition to which thatsection pertains, and wherein each section has a surface which residesbetween the respective first and second ends.

According to a fourth aspect of the present invention, an apparatus isprovided which selectively forms a tool. The apparatus includes a toolmodel forming portion; a press which is coupled to the tool modelforming portion; a section forming portion which is coupled to the toolmodel forming portion and to the press and which forms sections by useof the tool model and which selectively stacks the formed sectionswithin the press; and a measurement portion which measures the thicknessof the stacked sections and which generates a signal, based on thethickness measurement, and which communicates the signal to the modelforming portion.

These and other features, aspects, and advantages of the presentinvention will become apparent by a review of the following detaileddescription of the preferred embodiment of the invention and byreference to the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a tool which is made inaccordance with the teachings of the preferred embodiment of theinvention and further illustrating a partition of the tool which is usedto form a section in the tool formation process of the preferredembodiment of the invention;

FIG. 2 is block diagram of a tool creation and/or forming apparatuswhich is made in accordance with the teachings of the preferredembodiment of the invention and which may be used to create the toolwhich is shown in FIG. 1;

FIG. 3 is a perspective view of a section which is created by the use ofthe tool partition which is shown in FIG. 1 and by the tool creationapparatus which is shown in FIG. 2;

FIG. 4 is a side view of the section which is shown in FIG. 3; and

FIG. 5 is a flowchart including a sequence of operational stepsperformed by the apparatus which is shown in FIG. 2 and cooperativelyforming the tool forming methodology of the preferred embodiment of theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

Referring now to FIG. 2, there is shown a tool creation and/or formingapparatus 10 which is made in accordance with the teachings of thepreferred embodiment of the invention. As shown, tool creation apparatus10 includes a computer or processor 12 which is operable under storedprogram control and which selectively creates and/or receives a computeraided design or a substantially “similar type of model” or intangiblemanifestation of a tool which is to be created. Such a model typicallyhas a three dimensional data format, including but not limited to datawhich specifies the surface features and contours necessary to allow theformed tool to produce a desired part or product. In one non-limitingembodiment, computer or processor 12 comprises a commercially availablecomputer, and the created and/or received model may form a threedimensional and relatively accurate picture of the tool.

Tool creation apparatus 10 further includes a laser cutter 14 which iscontrollably and communicatively coupled to the model creator andprocessor 12 and a material provider 16 which is communicatively andcontrollably coupled to the laser cutter 14 and to the model creator andprocessor 12. In one-non limiting embodiment of the invention, materialprovider 16 provides and transports sheets of material having a certaindesired and/or specified thickness and height to the laser cutter 14.Hence, in this non-limiting embodiment of the invention, sectionprovider 16 comprises a store of sheets of material and a placement andtransport apparatus (e.g., a robot and/or conveyor assembly) which, uponreceipt of commands from the model creator and processor 12,automatically places a sheet of material in operative close proximity tothe laser cutter 14.

Apparatus 10 further includes a section transporter 18 and a press 20.Particularly, section transporter 18 is controllably and communicativelycoupled to the laser cutter 14 and to the press 20 and, in onenon-limiting embodiment of the invention, comprises a robot and/orconveyor assembly and is effective to selectively transport sections,which are formed by the laser cutter 14 from the material provided bythe material provider 16, to the press 20. Transporter 18 (as well asthe transport functionality of provider 16) may be replaced by humanworkers or some other commercially available machinery. Hence, lasercutter 14, material provider 16, and section transporter 18cooperatively comprise, in one non-limiting embodiment, a “sectionforming” assembly. Cutter 14 may also comprise some other type ofconventional and commercially available apparatus.

Apparatus 10 further includes a bonding provider 22 which iscommunicatively and controllably coupled to the model creator andprocessor 12 and to the press 20, and a thickness measurement apparatus24 which is operatively and communicatively coupled to the press 20 andto the model creator and processor 12.

Particularly, bonding provider 22 comprises a store and/or quantity ofbonding material and an application portion or apparatus (e.g., a robot)which is adapted to selectively apply the bonding material to thevarious sections which are received by and/or within the press 20, uponthe receipt of certain command signals from the model creator andprocessor 12. Thickness measurement device 24 is adapted to, upon thereceipt of certain command signals from the model creator and processor12, measure the thickness of the various sections which are residentwithin the press 20 and to communicate such measurements to the modelcreator and processor 12. The press 20 is adapted to selectively applypressure to or “pressurize” the various sections which it receives andcooperates with the bonding material to cause the contained sections tocooperatively form a desired tool. In one non-limiting embodiment of theinvention, boding provider 22 is not used. Rather, the sections areselectively “joined” or “bonded” only by press 20. Thickness measurermay comprise a commercially available laser or light measurement systemor some other conventional device.

The operation of the tool creation apparatus 10 will now be furtherexplained with reference to the tool 40 which is shown in FIG. 1 andwhich comprises a structure having a cavity 42 and at least one“rolling” or substantially uneven surface 44. The following explanationwill further utilize the conventional “x”, “y”, and “z” coordinatesystem which is also shown in FIG. 1.

It should be appreciated that while the following discussion utilizesthe tool 40 which is shown in FIG. 1, nothing in this Application ismeant to nor should limit the applicability of the apparatus 10 and/orthe method of the invention to only a tool which is substantiallysimilar to tool 40. Rather, the apparatus 10 and the tool formingmethodology of the preferred embodiment of the invention may be used toselectively and rapidly and accurately construct a wide variety ofdissimilar tools and objects. Reference is now made to methodology orflowchart 50, shown in FIG. 5, which comprises the tool creationmethodology of the preferred embodiment of the invention and which isused by the tool forming apparatus 10.

Methodology 50 begins with a first step 52 in which a multi-dimensionalmathematical and/or computer model of a tool is created. Particularly,the model, as known to those in the art, seeks to intangibly replicate atool, such as tool 40. The model may be selectively created by the modelcreator and processor 12 or created by another apparatus (not shown),such as a conventional computer aided design or “CAD” apparatus, andcommunicated to or “exported to” the model creator and processor 12. Themodel may “look like” and be substantially similar in appearance to thestructure which is depicted within FIG. 1. Step 54 follows step 52 and,in this step 54, a portion of the model is selected and this portiondefines a partition (e.g., a “partition” is a cross sectional portion ofthe model). That is, in one non-limiting embodiment of the invention,the user of apparatus 10 and/or the model creator and processor 12selects (“replicates”) one of the ends of the model of tool 40 whichcorresponds to one of the ends 46, 48, and then sequentially createsunique partitions of the model in a direction toward the other“unselected” end 46, 48 until the entire model has been traversed. Eachpartition, such as the initial partition 51, therefore corresponds to aunique cross sectional area of the tool 40. Moreover, the user ofapparatus 10 (or the processor 12) specifies a predetermined thickness49 for each such partition. Step 56 follows step 54 and, in this step56, a physical section is created which is based upon and represents thephysical manifestation of the first designated and/or defined modelpartition 51.

In step 56, material having a thickness 49 is provided by the provider16 and transported to the laser cutter 14 in order to allow thespecified and/or designed section to be physically created. That is,model creator and processor 12 creates a cutting program to cause thelaser cutter 14 to form the provided material into the shape of thisfirst defined partition 51, including slot 55 and air and/or coolingpassages 57. The material may comprise steel or some other desiredmaterial.

Particularly, edges 58, 60 of the tool partition 51 respectivelycorrespond to, (e.g., are used to construct in the following manner), inthis example, edges 62 and 64 of section 66. Each edge 62, 64 is made tohave a substantially identical height or “z-direction value” equal. Thatis, various points 70 are defined by the model creator and processor 12along the edge 60. Similarly, various points 72 are defined along theedge 58. Each point 72 uniquely corresponds with or to (e.g., issubstantially co-linear to) one of the points 70. The height or the“z-dimension” value for each pair of corresponding points 70, 72 iscompared and the point 70, 72 having the lowest height is “modified” byhaving its height increased to equal the height of the other point 70,72. In this manner, each pair of corresponding points 70, 72 has asubstantially identical height which is equal to the largest heightassociated with or provided by the points 70, 72, and these modifiedpoints 70, 72 cooperatively define modified edges 58, 60. In onenon-limiting embodiment, there is substantially no space between points70 and substantially no space between points 72. The points 70, 72 arethen respectively used to define the height of edges 64, 62. That is,the two modified edges 58, 60 (e.g., the modified points 70, 72) areoverlayed to form a two dimensional edge and edges 64, 62 are made to besubstantially similar to this two dimensional edge. In some alternateembodiment, the foregoing procedure is modified by causing the opposingedges 62, 64, at each pair of corresponding points 72, 70, to have aheight which is substantially identical to the greatest height of anysurface or portion of the model which resides between these pairs ofcorresponding points. That is, each pair of corresponding points 70, 72is made to have a substantially identical height which is equal to thegreatest height of any surface which resides between them and isco-linear to them. This alternative procedure is used when partitions ofrelatively large widths are used. In yet another non-limitingembodiment, each pair of corresponding points 70, 72 is made to have aheight which is the greatest of the height of any of the twocorresponding points 70, 72 and any surface which is between andco-linear to them. These “modified” points 70, 72 then form, withinprocessor 12, a two dimensional line which become the cutting path forthe laser cutter 14. The foregoing “modification” allows for theinclusion of surface counters necessary to allow the formed tool toperform the desired function and yet allows the tool to be rapidlyformed.

The laser cutter 14 then forms the provided material in the manner,thereby creating section 66 from the partition 51 (e.g., surface 68 maybe typically formed by a subsequent operation which may be accomplishedby a conventional machine). Step 80 then follows step 56 and, in thisstep 80, the thickness measurer 24 measures the thickness or “xdirection value” of the formed section 66 and provides the measurementto the model creator and processor 12. Step 82 follows step 80 and, inthis step 82, the model creator and processor 12 uses the thicknessmeasurement value to determine the amount of the model which has beenreplicated. That is, the model creator and processor 12 compares anduses the measured “x” direction value to fix a location within the modelwith which to create a new cross sectional partition within (e.g., theapparatus 10 will not attempt to replicate an already existing portionof the model). In this manner, structural variances within the providedmaterial as well as other variances associated with such items as thebonding material which may increase the thickness of the createdstructure may be accounted for (e.g., the processor 12 may dynamicallybecome aware of the fact that a larger amount of the model has beenphysically created and dynamically adjust to this situation by movingthe site of the next partition to be created). Hence, these thicknessmeasurement signals comprise dynamic positive feedback signals whichallow tools to be rapidly and accurately made. This procedure alsoallows for the use of sections with varying thicknesses (e.g., theprocessor and model creator 12 may dynamically adjust and specifysubstantially any thickness for the created partition and section),thereby reducing production cost, and provides a “quick” or timelywarning of inaccuracies with the produced structure. The positivefeedback signal, in one non-limiting embodiment, is provided after eachsection is made, thereby providing timely notification of undesiredlarge variances between the thickness of the created structure and theamount of the model which may desired to be replicated by thisstructure.

Step 84 follows step 82 and, in this step 84, another partition of themodel may be taken in substantially the same manner as was previouslydelineated. Step 86 follows step 84 and, in this step, a section iscreated for this partition in the previously delineated manner. Thenewly created section is transported to the press 20, by portion 18, andis bonded to the previously deposited section. Step 90 follows step 88and, in this step, the model creator and processor 12 determines whetherthe model has been completed. If the model has not been completed, step90 is followed by step 80 in which the thickness of the bonded sectionis measured. This “thickness” feedback allows the processor 12 todynamically learn of the amount the model that has been constructed andto compare the measured value with the theoretical or intangible valuescontained within the processor 12. Such comparison may cause processor12 to determine that the tool has been incorrectly made and allow theprocessor 12 to quickly warn the user and/or recommend other correctiveactions. Partitions and sections are created and selectively bonded bythe previously described steps 80, 82, 84, 86, and 88, to the thenexisting structure until the tool is made. The methodology 50 is endedat step 92.

It should be appreciated that the invention is not limited to the exactconstruction or method which has been illustrated and discussed above,but that various changes and modifications may be made without departingfrom the spirit and the scope of the invention as is more fullydelineated in the following claims.

1. A method for creating a tool, said method comprising the steps ofcreating a model of the tool; creating a first partition of the model;forming a first section from said first partition, said first partitionincluding a passageway; measuring said first section; using saidmeasurement to create a second partition of the model; forming a secondsection from said partition; and attaching said second section to saidfirst section only after said second section is completely formed,thereby forming said tool.
 2. The method of claim 1 wherein said secondsection has a height which is dependent upon said first section.
 3. Themethod of claim 1 wherein said second section has a width which isdependent upon said first section.
 4. The method of claim 1 wherein saidpassageway comprises an indentation.